H. Santos, E. Perondi, A. V. Wentz, Anselmo Luis da Silva Júnior, D. Barone, M. Galassi, B. Castro, André Ferreira, N. R. S. D. Reis, H. Pinto, Lincoln Homero Thomé Ferreira
Two major concerns in offshore production are Methane Hydrates and Paraffin Plugs. They may stop wells for months, causing high financial losses. Sometimes, depressurization techniques allow hydrate removal. Another strategy is using coiled tubing or a similar unit to perform local heating or solvent injection. However, frequently these strategies are not successful. In those cases, a rig may be a suitable but expensive solution, or the line may be lost. The present project aimed to develop a robotic system capable of performing controlled local heating for removing Paraffin and Methane Hydrates. The robotic system accesses the line from the production platform. It uses a peristaltic self-locking traction system to exert high traction forces. An umbilical with quasi-neutral buoyancy and low friction coefficient reduces the cable traction. It also allows moving upwards and in pipes with a large number of curves, something that coiled tubing and similar units cannot. Carbon fiber vessels and compact circuits allowed downsizing it to move inside 4-inch flexible pipes. Initially, a theoretical model for the local heating system allowed the evaluation of this strategy. A prototype allowed testing the system in a cooled environment. This heating system removes the obstruction in a controlled manner, avoiding damages to the polymeric layer of the flexible line. Simultaneously, a modified Euler-Eytelwein equation allowed the development of a theoretical model for cable traction. Experimental tests validated this model. Those tests used straight and curved pipes, both empty and filled with fluid and using different loads. Also, the 20 kN (4.3 kip) traction system was modeled theoretically considering the self-locking system, the contact with the wall, and a diameter range. Prototypes allowed the comparison between electric and hydraulic systems. Those prototypes also validated the traction capacity. Besides, force transmission from the traction system to the umbilical occurs through an external aramid layer. A Universal Testing Machine validated the traction resistance of the external layer. Furthermore, carbon fiber vessels protect the electronic circuits from oil and external pressure. The power electronics designed can provide up to 4kW for the motors to operate the hydraulic system. The onboard computer runs with a real-time operational system and, together with a sensors network, is responsible for monitoring the pressures, temperatures, currents and tensions throughout the entire robot. The fail-safe design allows the robot to operate without risks of catastrophic accidents and guarantees that it can be pulled out at any time. A pressure vessel validated the collapse resistance, reaching more than 700 bar (10.000 psi). In addition, exhaustive integration tests validated the onboard electronics and the surface control system. Finally, factory tests validated the umbilical design.
海上生产的两个主要问题是甲烷水合物和石蜡塞。他们可能会关闭油井数月，造成巨大的经济损失。有时，减压技术可以去除水合物。另一种方法是使用连续油管或类似装置进行局部加热或溶剂注入。然而，这些策略通常都不成功。在这种情况下，钻井平台可能是一个合适但昂贵的解决方案，否则可能会丢失管线。目前的项目旨在开发一个机器人系统，能够执行控制局部加热去除石蜡和甲烷水合物。机器人系统从生产平台进入生产线。它采用蠕动自锁牵引系统，以施加高牵引力。具有准中性浮力和低摩擦系数的脐带缆减少了电缆牵引力。它还允许向上移动和在管道中有大量的曲线，这是连续油管和类似的装置所不能做到的。碳纤维容器和紧凑的电路可以缩小尺寸，使其在4英寸的柔性管道中移动。最初，局部供暖系统的理论模型允许对该策略进行评估。一个原型允许在冷却环境中测试系统。这种加热系统以可控的方式去除障碍物，避免损坏柔性管线的聚合物层。同时，修正的欧拉-埃特尔魏因方程使缆索牵引的理论模型得以发展。实验验证了该模型的有效性。这些测试使用了直管和弯管，空管和充管都使用了不同的载荷。此外，考虑自锁系统、与壁面的接触以及直径范围，对20 kN (4.3 kip)牵引系统进行了理论建模。原型机允许在电动和液压系统之间进行比较。这些原型也验证了牵引能力。此外，从牵引系统到脐带的力传递是通过外部芳纶层进行的。通用试验机验证了外层的牵引阻力。此外，碳纤维容器保护电子电路免受油和外部压力的影响。设计的电力电子设备可以为马达提供高达4kW的功率来操作液压系统。机载计算机与实时操作系统一起运行，并与传感器网络一起负责监控整个机器人的压力、温度、电流和张力。故障安全设计使机器人的操作没有灾难性事故的风险，并保证它可以在任何时候被拉出来。一个压力容器验证了抗坍塌性，达到了700 bar (10,000 psi)以上。此外，详尽的集成测试验证了机载电子设备和地面控制系统。最后，工厂测试验证了脐带缆的设计。
{"title":"Proposal and Experimental Trials on a Robot for Hydrate and Paraffin Removal in Submarine Flexible Lines","authors":"H. Santos, E. Perondi, A. V. Wentz, Anselmo Luis da Silva Júnior, D. Barone, M. Galassi, B. Castro, André Ferreira, N. R. S. D. Reis, H. Pinto, Lincoln Homero Thomé Ferreira","doi":"10.4043/30663-ms","DOIUrl":"https://doi.org/10.4043/30663-ms","url":null,"abstract":"Two major concerns in offshore production are Methane Hydrates and Paraffin Plugs. They may stop wells for months, causing high financial losses. Sometimes, depressurization techniques allow hydrate removal. Another strategy is using coiled tubing or a similar unit to perform local heating or solvent injection. However, frequently these strategies are not successful. In those cases, a rig may be a suitable but expensive solution, or the line may be lost. The present project aimed to develop a robotic system capable of performing controlled local heating for removing Paraffin and Methane Hydrates. The robotic system accesses the line from the production platform. It uses a peristaltic self-locking traction system to exert high traction forces. An umbilical with quasi-neutral buoyancy and low friction coefficient reduces the cable traction. It also allows moving upwards and in pipes with a large number of curves, something that coiled tubing and similar units cannot. Carbon fiber vessels and compact circuits allowed downsizing it to move inside 4-inch flexible pipes. Initially, a theoretical model for the local heating system allowed the evaluation of this strategy. A prototype allowed testing the system in a cooled environment. This heating system removes the obstruction in a controlled manner, avoiding damages to the polymeric layer of the flexible line. Simultaneously, a modified Euler-Eytelwein equation allowed the development of a theoretical model for cable traction. Experimental tests validated this model. Those tests used straight and curved pipes, both empty and filled with fluid and using different loads. Also, the 20 kN (4.3 kip) traction system was modeled theoretically considering the self-locking system, the contact with the wall, and a diameter range. Prototypes allowed the comparison between electric and hydraulic systems. Those prototypes also validated the traction capacity. Besides, force transmission from the traction system to the umbilical occurs through an external aramid layer. A Universal Testing Machine validated the traction resistance of the external layer. Furthermore, carbon fiber vessels protect the electronic circuits from oil and external pressure. The power electronics designed can provide up to 4kW for the motors to operate the hydraulic system. The onboard computer runs with a real-time operational system and, together with a sensors network, is responsible for monitoring the pressures, temperatures, currents and tensions throughout the entire robot. The fail-safe design allows the robot to operate without risks of catastrophic accidents and guarantees that it can be pulled out at any time. A pressure vessel validated the collapse resistance, reaching more than 700 bar (10.000 psi). In addition, exhaustive integration tests validated the onboard electronics and the surface control system. Finally, factory tests validated the umbilical design.","PeriodicalId":10925,"journal":{"name":"Day 3 Wed, May 06, 2020","volume":"14 1","pages":""},"PeriodicalIF":0.0,"publicationDate":"2020-05-04","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"86711423","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
As Additive Manufacturing (AM) progresses forward to industrial production, there is a predominant need for standardization to ensure consistency and reliability. Development of industry accepted standards and guidelines is necessary for qualification and certification of AM parts across several industries. AM affords several advantages when compared to conventional manufacturing, including weight reduction, part consolidation, design freedom and inventory reduction, and has demonstrated its potential in industries such as aerospace. Since it is a relatively new manufacturing technology, there is a lack of testing and inspection procedures specific to AM, which hinders the development of standards. Existing testing procedures were developed for traditionally manufactured parts that are not directly applicable to AM processes. A number of Standards Development Organizations are working towards developing guidelines and standards for various processes in the AM value chain. An overview of the current status of Standard Development Organization's activities in the field of AM will be presented, focusing on gaps and industry specific requirements. Specifically for applications in oil and gas, pertinent standards need to be developed to enhance operational and environmental safety, efficiency and sustainability.
{"title":"Standardization of Additive Manufacturing for Oil and Gas Applications","authors":"L. Vendra, Ameen Malkawi, A. Avagliano","doi":"10.4043/30533-ms","DOIUrl":"https://doi.org/10.4043/30533-ms","url":null,"abstract":"\u0000 As Additive Manufacturing (AM) progresses forward to industrial production, there is a predominant need for standardization to ensure consistency and reliability. Development of industry accepted standards and guidelines is necessary for qualification and certification of AM parts across several industries. AM affords several advantages when compared to conventional manufacturing, including weight reduction, part consolidation, design freedom and inventory reduction, and has demonstrated its potential in industries such as aerospace. Since it is a relatively new manufacturing technology, there is a lack of testing and inspection procedures specific to AM, which hinders the development of standards. Existing testing procedures were developed for traditionally manufactured parts that are not directly applicable to AM processes. A number of Standards Development Organizations are working towards developing guidelines and standards for various processes in the AM value chain. An overview of the current status of Standard Development Organization's activities in the field of AM will be presented, focusing on gaps and industry specific requirements. Specifically for applications in oil and gas, pertinent standards need to be developed to enhance operational and environmental safety, efficiency and sustainability.","PeriodicalId":10925,"journal":{"name":"Day 3 Wed, May 06, 2020","volume":"41 1","pages":""},"PeriodicalIF":0.0,"publicationDate":"2020-05-04","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"88026080","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
I. Jamaludin, Ainul Azuan Masngot, M. H. Basir, A. Abdullah, Ahmad Zulfadzli Ahmad Murad, D. Arsanti
PNPR cluster consists of three fields, namely PX, NX and PR (combined STOIIP ~200 MMstb), located ~300 km offshore of Peninsular Malaysia. Throughout its journey of monetizing marginal waxy crude, many challenges and hurdles have arisen, including sustaining oil production rate above economic threshold, pipeline clogging, and FPSO fuel uncertainties, which requires collaboration between surface and subsurface team to develop unique solutions in managing these downturns. Critically, PNPR cluster is expected to reach economic limit within few years’ time. This paper will elaborate on how IOR is achieved in PNPR cluster, historically and in near future. Ever since first production by PX and NX in 2004, infill drilling campaigns have been needed to sustain production above the economic limit of 5,000 bopd. Later in 2009, approximately a year after PR kicked off its first oil; the14 km pipeline to FPSO was plugged due to wax accumulation as a result of prolonged shutdown. A pipeline restoration project was embarked on involving installation of pipe in pipe (PiP), which utilizes hot water circulation as pipeline heating element. Another complexity has been consistently supplying gas to the FPSO for fuel, which involves a cement packer and adding perforation jobs in gas wells. Additionally, the waxy crude in these fields requires gas lift to be produced, particularly after water production started to escalate. This gives an opportunity to introduce through tubing electrical submersible pump (TTESP) to the field, while reducing dependence on gas lift. Financial wise, cost optimization initiatives are necessary to maintain the operability of the fields. To date, five infill projects have been successfully completed, contributing to IOR by bouncing back PNPR oil production rate. Additionally, a gas cap blow down (GCBD) from NX J80 reservoir also managed to improve reservoir recovery factor (RF) while supplying additional gas for fuel. Meanwhile, the PiP system, an enabler for IOR, has successfully ensures smooth crude oil delivery above pour point temperature from PR Platform to FPSO. In terms of gas fuel supply forecast, proper gas wells production phasing is planned to secure steady supply until 2023. IOR through artificial lift, TTESP is planned to be executed soon in one idle production well with potential gain of 500 bopd, hence eliminating option to workover the well, which is costly. Viewing IOR from economic standpoint, operating expenditure (OPEX) reduction through new philosophies were implemented, including reduction of FPSO charting rate, proactive maintenance and low-cost chemical bull heading, resulting in better cash flow for PNPR. It is expected that existing PNPR wells can recover 2 MMstb of oil through extension of economic life via incoming infill drilling in 2021, translating into 1-2% increase from current RF. Moreover, PX and NX already produced ~80% more reserves than originally booked in the first FDP.
{"title":"IOR in a Waxy, Marginal Fields, Offshore Malaysia Environment; Past Efforts and Future Outlook ߝ A Case Study","authors":"I. Jamaludin, Ainul Azuan Masngot, M. H. Basir, A. Abdullah, Ahmad Zulfadzli Ahmad Murad, D. Arsanti","doi":"10.4043/30856-ms","DOIUrl":"https://doi.org/10.4043/30856-ms","url":null,"abstract":"\u0000 PNPR cluster consists of three fields, namely PX, NX and PR (combined STOIIP ~200 MMstb), located ~300 km offshore of Peninsular Malaysia. Throughout its journey of monetizing marginal waxy crude, many challenges and hurdles have arisen, including sustaining oil production rate above economic threshold, pipeline clogging, and FPSO fuel uncertainties, which requires collaboration between surface and subsurface team to develop unique solutions in managing these downturns. Critically, PNPR cluster is expected to reach economic limit within few years’ time. This paper will elaborate on how IOR is achieved in PNPR cluster, historically and in near future.\u0000 Ever since first production by PX and NX in 2004, infill drilling campaigns have been needed to sustain production above the economic limit of 5,000 bopd. Later in 2009, approximately a year after PR kicked off its first oil; the14 km pipeline to FPSO was plugged due to wax accumulation as a result of prolonged shutdown. A pipeline restoration project was embarked on involving installation of pipe in pipe (PiP), which utilizes hot water circulation as pipeline heating element. Another complexity has been consistently supplying gas to the FPSO for fuel, which involves a cement packer and adding perforation jobs in gas wells. Additionally, the waxy crude in these fields requires gas lift to be produced, particularly after water production started to escalate. This gives an opportunity to introduce through tubing electrical submersible pump (TTESP) to the field, while reducing dependence on gas lift. Financial wise, cost optimization initiatives are necessary to maintain the operability of the fields.\u0000 To date, five infill projects have been successfully completed, contributing to IOR by bouncing back PNPR oil production rate. Additionally, a gas cap blow down (GCBD) from NX J80 reservoir also managed to improve reservoir recovery factor (RF) while supplying additional gas for fuel. Meanwhile, the PiP system, an enabler for IOR, has successfully ensures smooth crude oil delivery above pour point temperature from PR Platform to FPSO. In terms of gas fuel supply forecast, proper gas wells production phasing is planned to secure steady supply until 2023. IOR through artificial lift, TTESP is planned to be executed soon in one idle production well with potential gain of 500 bopd, hence eliminating option to workover the well, which is costly. Viewing IOR from economic standpoint, operating expenditure (OPEX) reduction through new philosophies were implemented, including reduction of FPSO charting rate, proactive maintenance and low-cost chemical bull heading, resulting in better cash flow for PNPR. It is expected that existing PNPR wells can recover 2 MMstb of oil through extension of economic life via incoming infill drilling in 2021, translating into 1-2% increase from current RF. Moreover, PX and NX already produced ~80% more reserves than originally booked in the first FDP.","PeriodicalId":10925,"journal":{"name":"Day 3 Wed, May 06, 2020","volume":"83 5 1","pages":""},"PeriodicalIF":0.0,"publicationDate":"2020-05-04","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"87651720","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Offshore industry assets are capital intensive and downtime can have severe financial consequences. Additive manufacturing (AM) based supply chains can potentially offer offshore industry stakeholders a strong value and a competitive advantage, from lower costs and lead times to greater flexibility and agility. However, the current adoption level of AM for the offshore industry is very limited, despite the consensus that such technology could have potential applications for spare parts, repair and even new builds. While adoption of additive manufacturing could be a source of positive change, inadequate understanding of requirements regarding approval, qualification and certification processes required by regulatory authorities could hinder the progress of AM adoption in the offshore industry. Currently, there are only a handful of additive manufacturing standards available for early adopters of AM technology. Hence, costly and time-consuming nonstandard testing to ensure the integrity of the 3D printed parts is deterring the wider applications of additive manufacturing in the offshore sector, underscoring the need to develop optimal practice guidelines and standards from design to part build to operation. This paper aims to highlight several key challenges that hinder the adoption of AM in the offshore sector and to propose various solutions that can help to overcome these. Due to its novel approach, the risk-based certification pathway discussed in this paper will help the offshore industry and its supply chain ecosystem to build trust and confidence in the adoption of this emerging technology, which otherwise might not be possible.
{"title":"Certification Pathway for 3D Printed Parts - Unlocking the Barriers to Accelerate the Adoption of Additive Manufacturing in Offshore Industry","authors":"S. Kandukuri, Brice Le Gallo","doi":"10.4043/30671-ms","DOIUrl":"https://doi.org/10.4043/30671-ms","url":null,"abstract":"\u0000 Offshore industry assets are capital intensive and downtime can have severe financial consequences. Additive manufacturing (AM) based supply chains can potentially offer offshore industry stakeholders a strong value and a competitive advantage, from lower costs and lead times to greater flexibility and agility. However, the current adoption level of AM for the offshore industry is very limited, despite the consensus that such technology could have potential applications for spare parts, repair and even new builds. While adoption of additive manufacturing could be a source of positive change, inadequate understanding of requirements regarding approval, qualification and certification processes required by regulatory authorities could hinder the progress of AM adoption in the offshore industry.\u0000 Currently, there are only a handful of additive manufacturing standards available for early adopters of AM technology. Hence, costly and time-consuming nonstandard testing to ensure the integrity of the 3D printed parts is deterring the wider applications of additive manufacturing in the offshore sector, underscoring the need to develop optimal practice guidelines and standards from design to part build to operation.\u0000 This paper aims to highlight several key challenges that hinder the adoption of AM in the offshore sector and to propose various solutions that can help to overcome these. Due to its novel approach, the risk-based certification pathway discussed in this paper will help the offshore industry and its supply chain ecosystem to build trust and confidence in the adoption of this emerging technology, which otherwise might not be possible.","PeriodicalId":10925,"journal":{"name":"Day 3 Wed, May 06, 2020","volume":"14 1","pages":""},"PeriodicalIF":0.0,"publicationDate":"2020-05-04","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"74094234","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
{"title":"On the Moors with Ted Hughes and Ovid","authors":"","doi":"10.1144/geosci2020-082","DOIUrl":"https://doi.org/10.1144/geosci2020-082","url":null,"abstract":"","PeriodicalId":10925,"journal":{"name":"Day 3 Wed, May 06, 2020","volume":"26 1","pages":""},"PeriodicalIF":0.0,"publicationDate":"2020-05-04","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"81081723","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
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